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Project 'Hole in the Pocket'

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Old 10-04-2014 | 10:02 PM
  #526  
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From: Hudson, FL
Year: 1999
Model: Cherokee
Engine: 4.0L Inline 6
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Originally Posted by Chuck82
Is it the frame side mount that won't free from the track bar itself?
No, it's the axle side.

I'm using an aftermarket bolt with a nut, and the nut is enclosed in the factory bracket. No more flag-nut.

And, the head of the bolt is completely rounded out. I've tried notching it, and bashing an impact socket over it and tried spinning it with the chatter of an air gun. No good. The metal of the bolt is too soft.

It'll be ugly if the bolt breaks, because there's no room on the rear to put a wrench on the nut.

The only thing I haven't tried yet is welding something to the head of the bolt, and I'm afraid the bolt will break because that'll change the temper of the bolt, which is already soft.
Old 10-04-2014 | 10:17 PM
  #527  
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From: Sparks, Nv
Year: 1999
Model: Cherokee
Engine: 4.0 I6
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Originally Posted by thatXJguy
No, it's the axle side. I'm using an aftermarket bolt with a nut, and the nut is enclosed in the factory bracket. No more flag-nut. And, the head of the bolt is completely rounded out. I've tried notching it, and bashing an impact socket over it and tried spinning it with the chatter of an air gun. No good. The metal of the bolt is too soft. It'll be ugly if the bolt breaks, because there's no room on the rear to put a wrench on the nut. The only thing I haven't tried yet is welding something to the head of the bolt, and I'm afraid the bolt will break because that'll change the temper of the bolt, which is already soft.
The only thing I can possibly think of is using these if you haven't tried already they're made by Irwin I used them to get my studs out and they saved me a lot of time dealing with what you're dealing with but mine were the UCA bolts (PITA) you can find them at any auto parts store they basically tear right into the bolt.

Project 'Hole in the Pocket'-image-2049954805.jpg
Old 10-04-2014 | 10:27 PM
  #528  
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Originally Posted by Chuck82
The only thing I can possibly think of is using these if you haven't tried already they're made by Irwin I used them to get my studs out and they saved me a lot of time dealing with what you're dealing with but mine were the UCA bolts (PITA) you can find them at any auto parts store they basically tear right into the bolt.

Attachment 255002
I saw those right next to the extraction kit I pictured above. I basically did the same thing by hammering an impact socket over the bolt, and it just rounded the thing out. I guess I have nothing to lose from trying that set (the helix design might be better and more effective), but next step is just cutting and welding LOL.
Old 10-04-2014 | 10:34 PM
  #529  
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From: Sparks, Nv
Year: 1999
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Originally Posted by thatXJguy
I saw those right next to the extraction kit I pictured above. I basically did the same thing by hammering an impact socket over the bolt, and it just rounded the thing out. I guess I have nothing to lose from trying that set (the helix design might be better and more effective), but next step is just cutting and welding LOL.
That track bar must be a huge PITA! And yeah the Irwin set bro just straight cuts into the bolt it's crazy I really like them. And yeah I always try to avoid cutting stuff unless I really really have too. At least you have a welder though that's one thing I'm missing
Old 10-05-2014 | 03:22 AM
  #530  
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From: Mountain Town, USA
Year: 1991
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Well I just stayed up and read through all 36 pages and I gotta say, you have one of the cleanest, nicest late model XJ's on the whole forum!


Top notch my friend!

Definitely sub'd!





......and off to bed lol
Old 10-05-2014 | 10:21 PM
  #531  
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The AC blows colder than ever after that re-charge, and the heat finally works again, yay!
Old 10-06-2014 | 11:28 AM
  #532  
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I'm lucky I didn't have a vehicle fire yesterday. I guess I accidentally switched the positive and relay wires for the 12-inch light bar when putting the dash back together, and suddenly there was a bunch of smoke in the cabin when I turned it on.

I quickly ran to the garage and got the 13mm to disconnect the battery and then let it cool off, and then removed the melted wire:



I have a replacement harness on the way already!

Also, my Hi-lift jack and Lift mate came today:



The River Raider brackets to mount it behind my rear seat should be here tomorrow.
Old 10-07-2014 | 04:00 PM
  #533  
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My new River Raider XJ rear-seat mounts for the Hi-Lift jack came via UPS today. Here they are:



Installed them one-by-one in the factory rear seat bracket locations:




And bolted up the Hi-Lift jack (it's held on by wing nuts for finger-tight holding):



I wasn't thinking my spare tire would fit... but I'll be damned... it did...

Old 10-07-2014 | 05:30 PM
  #534  
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I now have some 1.5-inch coil spacers coming to help level out the front of the vehicle to get rid of the "rake" I have.
Old 10-08-2014 | 09:32 PM
  #535  
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Replacement 12-inch LED light bar wiring harness came today, as well as the Hi-lift jack handle isolator:



Also, an ATP exhaust manifold replacement to fix my cracked one:

Old 10-09-2014 | 04:36 PM
  #536  
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Some 1.5-inch coil spacers to fix the "rake" my front end has:

Old 10-09-2014 | 09:56 PM
  #537  
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I got my light bar harness re-wired. Works great again. Woot!
Old 10-11-2014 | 09:04 AM
  #538  
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Finally got the stripped out track bar bolt out with a shallower socket. The forged one is installed now. Also instead of using the provided bolt for the track bar, I decided to go ahead and use a factory flag nut again to prevent that from happening ever again.

Last edited by thatXJguy; 10-11-2014 at 11:19 AM.
Old 10-12-2014 | 10:55 PM
  #539  
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Today I installed the new exhaust manifold:


Old 10-12-2014 | 11:02 PM
  #540  
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Year: 1999
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Got my new forged track bar installed:



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